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No NB Yellow Trifecta :(
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Discussion Starter #1 (Edited)
This DIY is for Replacing the Ribbed Belt (aka Serpentine Belt) of the AEG 2.0 Liter Engine.

If you want to remove the Ribbed Belt Tensioner, that DIY is here...

DISCLAIMER: The author(s) assume that you (the reader) are reasonably capable with the automotive tools necessary to get the job accomplished, which means that you won’t glue your fingers together or use a cutting torch to get the bad part out and are smart enough to know not to try to blame or post ranting about anyone else if something goes horribly wrong ... AGREED?

These instructions were developed using the following NB...

1) 1999 AEG 2.0 Liter, 5 speed, O2J-EKG Transmission

As always, just remember to offer a simple thank you and credit to the original author (D2Beetle) when you tell all of your BUG buddies!!

TIME NEEDED: 10 Minutes

ITEMS NEEDED: An eBahn Bentley DVD and/or Haynes Manual.

PROJECT COST: Tools and Parts $54.15 (Does not include shipping or taxes)
... Special Tools $25.65
... Serpentine Belt $28.50 (Multi-rib belt, dual sided, 21.18 x 1195mm)

SPECIAL TOOLS: Volkswagen Special Tools and Equipment Program ...
... Connecting Rod Support 3090 $22.65

SPECIAL TOOLS Substitution: Nail, Allen Wrench or similar tool. Just be sure that what ever you use does not bend easily; there is a lot of tension on the lock pin.

TECHNICAL NOTES: It is not necessary to buy the special tool. A 4mm Allen Wrench or a 5/32 Drill Bit or even a nail of equivalent size will work as an effective substitute.

WARNINGS: The tensioner can produce a significant amount tension, never let it snap back into place, as this could possibly cause damage to the tensioner and injury to the mechanic.

CAUTIONS: If you plan to re-use the old belt, you must mark the direction of rotation and reinstall the belt in that direction. The reason for doing this is so the belt does not snap.

MISC Information: None.

So let’s begin ...
 

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No NB Yellow Trifecta :(
Joined
·
5,639 Posts
Discussion Starter #2 (Edited)
Step One: Remove the Engine Cover. Pull out the dip stick and set aside. Remove bolts [SB 01-1 and 2]; you only need to loosen the last bolt [SB 01-4]. Lift up on the front of the engine cover and pull toward the front of the car.

Step Two: Release the tension on the ribbed belt (serpentine belt) tensioner. The top of the tensioner can be see in pic [SB 02]. It is not necessary to relocate the hose noted in pic [SB 02 and 03]. I did so it did not interfere with the pics; however if you want to relocate the hose, push down on the bottom lip of the hose clip (yellow oval) and pull the right side hose toward the front of the car.

The tensioner must be locked into place in order to change the belt and this accomplished by aligining the pin hole in the tensioner [SB 04]. Pic [SB 05] shows you the wrench I used; it is a simple, but large crescent wrench. Pic [SB 06] shows you the placement of the wrench; once the wrench is in place pull it toward the front of the car until the lock pin holes line up [SB 07]; hold the wrench steady and insert the pin (special tool 3090) [SB 08]. The gently release your wrench.

Technical Note: There will be some backwards travel and be careful as there is significant pressure for the tensioner to bend the lock pin.

Step Three: Remove the Ribbed Belt.

Installation is the reverse of removal.

Technical Note: There is a significant amount of tension on the lock pin for the tensioner; DO NOT pull the lock pin out, without first relieving the tension on the pin and then gently let the tensioner tension the belt.
 

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